AdBlue® tanks

We offer regeneration of AdBlue® tanks and the sale of reconditioned tanks for cars with HDi/BlueHDi engines. An innovative offer based on a method developed by our company repairs to AdBlue® tanks avoids the costly replacement of the urea solution tank with a brand new one. We specialise in reconditioning various models of AdBlue® tanks. used in PSA/Stellantis passenger cars and vans (e.g. Citroen, Peugeot, DS, Fiat, Opel). In the process regeneration of AdBlue® pumps and entire tanks, we use state-of-the-art equipment and technology as well as spare parts of the highest quality. The high quality is backed up by a 24-month unlimited mileage warranty.

Genesis and application of the SCR system

As environmental awareness and understanding of the negative impacts of air pollution on human health and ecosystems has grown, action has been taken to reducing emissions of harmful substances generated by motor vehicles.

All these efforts have been aimed at meeting increasingly stringent emission standards, set mainly by European regulators. These standards, such as the Euro standards, provide guidelines for the maximum permissible emission levels of various harmful substances. One of the key factors on which particular attention has been focused has become nitrogen oxides (NOx).

For example Euro VI standards, introduced in 2014, define a very stringent NOx emission limits for new cars and vans sold in the European Union. For diesel cars, this requires the use of advanced emission control technologies, including SCR systems.

Originally developed mainly for heavy-duty vehicles, the SCR system quickly found its way into passenger cars as well. Its origins lie in the need to effectively reduce NOx emissions through selective catalytic reduction, a chemical process that converts harmful nitrogen oxides into environmentally inert substances such as nitrogen and water.

Thanks to the SCR system, cars can effectively reduce NOx emissions with minimal impact on engine performance and driving comfort. Thus, the SCR system has become an indispensable part of today's cars, vans and trucks, helping to achieve sustainability goals by reducing the negative impact of road transport on the environment and public health. The correct operation of this system depends on the efficiency of the tank, so in the event of a breakdown it is essential to rapid repair of the AdBlue tankemissions standards and safe vehicle operation.

Construction and principle of operation of the SCR system

SCR system (Selective Catalytic Reduction) consists of several key components that work together to effectively reduce oxides of nitrogen (NOx) in the engine exhaust. Here is a description of the design and main components of the SCR system:

AdBlue® liquid tank: A tank containing a urea solution, most commonly called AdBlue® or DEF (Diesel Exhaust Fluid), which is injected into the exhaust gas stream to reduce NOx. This tank is usually located close to the fuel tank.

1. Dosing pump: A pump that delivers AdBlue® solution from the tank to the injector in the correct amount depending on the engine operating conditions. In the event of its failure, it is often necessary to regeneration of AdBlue® pumpsto make the system work properly.
2. SCR system controller: The electronic system responsible for controlling all components of the SCR system, including the metering pump, injector, sensors. The controller also monitors various engine parameters and driving conditions to ensure optimum SCR system efficiency.
3. AdBlue® injector: The component responsible for the precise dosage of the AdBlue® solution into the exhaust gas stream in the exhaust system. The injector is located upstream of the SCR catalytic converter.
4. SCR catalytic converter: The main component of the SCR system, which contains a catalyst composed of chemically active substances such as vanadium oxide on a zeolite substrate. It is here that the chemical reaction for the selective catalytic reduction of NOx takes place with ammonia from the AdBlue® fluid.
5. NOx sensors: Sensors that monitor the level of nitrogen oxides in the exhaust gas, located upstream and downstream of the SCR catalytic converter. The information from these sensors is used to control AdBlue® dosage and optimise SCR system operation.

Selective catalytic reduction (SCR) is a chemical process that reduces the pollutants produced by diesel engines. Specifically, SCR converts harmful nitrogen oxide (NOx) pollutants into nitrogen and water. The NOx reduction reaction occurs as the gases pass through the SCR catalytic converter chamber. Before entering the catalytic converter chamber, a reducer is injected (AdBlue® fluid), which mixes with the exhaust gas. The injected fluid acts as a catalyst to trigger the chemical reaction necessary to convert NOx into nitrogen and water. The fluid used in vehicles is called AdBlue® or DEF (Diesel Exhaust Fluid). With the right design, it is possible to efficient regeneration of the AdBlue® tankwhich restores full functionality of the entire SCR system.

AdBlue® fluid (DEF)

AdBlue® liquid is an aqueous urea solution prepared from 32.5% urea and 67.5% deionised water. AdBlue® (DEF) is stored in a tank, from where it is drawn during the operation of the vehicle. Owners of cars with small tanks need to top it up every 5,000 kilometres or so, and those with the largest tanks even every 20,000 kilometres.

AdBlue® fluid characteristics:

• Clear and odourless liquid classified as non-toxic and safe for transport and storage
• Recommended shelf life is 12 months
• Freezing point: -11 °C
• Hydrolysis occurs from +30 °C
• Crystallisation during drying can cause corrosion, so spills should be cleaned up with water
• Has a corrosive effect on iron, copper, bronze and some aluminium alloys

AdBlue® freezes at -11°C, so the hose and AdBlue® pump can freeze in cold regions. AdBlue® level and temperature sensors are also fitted in the tank to ensure that the AdBlue® is operating at the correct temperature at all times, so that it can be used safely. In order for the SCR exhaust gas aftertreatment system to operate at low temperatures, a sufficient amount of frozen DEF must be restored to a liquid state in the shortest possible time, ideally in the order of minutes.

In Europe, Regulation (EC) No 692/2008 specifies in Annex XVI, point 10, that DEF from a frozen tank with a core temperature of -15°C (5°F) must be available within 20 minutes of starting the engine. Therefore, most tanks are equipped with electric AdBlue® heaters.

Design and principle of operation of the AdBlue® tank

PSA/Stellantis brand vehicles with HDi/BlueHDi engines use tanks that incorporate several major components of the SCR system. These include:

1. AdBlue® tank with volume measuring system
2. Heating elements
3. Electronic controller to manage system operation
4. Dosing pump
5. Pressure accumulator
6. Solenoid valve
7. Pressure and temperature sensors

The system is starting to dose AdBlue® fluid into the exhaust system when the temperature of the exhaust gas reaches a sufficiently high value (usually around 175oC). A pump is then activated, which pressurises the AdBlue® into the injector, and this injects it directly into the exhaust system upstream of the SCR catalytic converter. Upstream of the catalytic converter, there is usually a mixer, which helps to properly mix the sprayed agent with the exhaust gas to ensure an efficient chemical reaction.

Find out what a professional repair of AdBlue tanks and regain the efficiency of your car's system.

Remanufacturing process of the AdBlue® tank

Technology regeneration of AdBlue® tanks is our in-house development, which was created through the work of the research and development team together with the technology department. The remanufacturing process is divided into stages, in which the individual steps, such as technical condition assessment, cleaning of the tank, disassembly of components, component diagnostics, component replacement, assembly and final functional testing, as well as quality control of the AdBlue® tank after the remanufacturing process, are carried out sequentially. The high standards of our process regeneration of AdBlue® tanksconfirmed by TUV ISO 9001 certification, provide a guarantee of fault-free component operation for a period of 24 months.

Regeneration of the AdBlue® tank consists of the following steps:

1. Preliminary verification
2. Tank cleaning
3. Verification after cleaning
4. Disassembly of components
5. Verification of tank components
6. Replacement of damaged and critical tank parts (mechanical parts, electronics, seals, etc.).
7. Assembly of components, completion of the tank
8. Final diagnostic test
9. Evaluation of functional test results
10. Final quality control.

Find out how fast and effective it can be regeneration of AdBlue pumps made by our experts.

Causes and types of damage to AdBlue® tanks

Repair of the AdBlue® tank most often concerns a problem such as:

1. Leaks: AdBlue® fluid leaks can be caused by mechanical damage to the tank, leaks in pipe connections or damaged seals.
2. Crystallisation: Crystallization of AdBlue® liquid can occur in the tank, especially if it is exposed to extremely low temperatures, which can lead to blockage of the lines or nozzles in the injection system. The phenomenon may be encouraged by the use of AdBlue® fluid of inadequate quality.
3. Use of other liquid (fuel, water): If a liquid other than AdBlue® is used, such as fuel or water, leakage can occur, which can lead to damage to the tank components and the entire AdBlue® injection system. 
4. Electronic/electrical faults: Electronic faults in the SCR system control system can lead to malfunction of the fluid level, temperature, pressure sensors or other electronic components, which can affect the efficiency and performance of the AdBlue® injection system.

In each of these situations it is helpful to AdBlue® tank repairwhich avoids the need for costly replacements.

The most common symptoms of failure are:

1. Message displayed on the instrument cluster - "UREA (or AdBlue) Exhaust aftertreatment system fault: Start-up prohibited for xxxx km".
2. At the same time, the UREA light is on or blinking, the engine fault light and SERVICE light are on.
3. The controller records error P20E800 (P20E8) - "AdBlue pressure - pressure too low".

In this case, a quick regeneration of AdBlue® pumps or full tank repair is the only way to avoid immobilisation of the vehicle

Regeneration of AdBlue® tanks with Turbo-Tec

W Turbo-Tec for years we have specialised in services such as regeneration of AdBlue® tanks i Repair of AdBlue® pumps. Our technological facilities allow us to accurately diagnose and effectively repair the faults that most commonly cause problems in the SCR system. Thanks to the experience of our engineers, each tank repair is carried out in accordance with stringent quality standards, and we back up the end result with a two-year, mileage-free guarantee. Choosing Turbo-TecYou can be sure that your vehicle will be fully operational and that you will avoid the high cost of replacing it with a new part.

Contact us today and check how repair of AdBlue® tanks can restore your car to full working order. Call or write - our experts will advise on the best solution for your car.